Installation Manual, Allen-Bradley FanMaster Energy Saving Package

124 Pages·2009·3.69 MB·English

by  Rockwell Automation

FanMaster™ Energy Saving Package
Installation Manual (v2.xx)
Important User Information Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation
and Maintenance of Solid State Controls (Publication SGI-1.1 available from your
local Rockwell Automation sales office or online at http://
www.rockwellautomation.com/literature) describes some important differences
between solid state equipment and hard-wired electromechanical devices. Because
of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
WARNING: Identifies information about practices or circumstances
! that can cause an explosion in a hazardous environment, which may lead
to personal injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and
understanding of the product.
ATTENTION: Identifies information about practices or circumstances
! that can lead to personal injury or death, property damage, or economic
loss. Attentions help you identify a hazard, avoid a hazard, and

recognize the consequences.
Shock Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g.,
drive or motor) to alert people that surfaces may be at dangerous
temperatures.
Rockwell Automation, Allen-Bradley, PanelView, PanelView Component, PowerFlex and MicroLogix are trademarks or registered trademarks of
Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual
Table of Contents
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Preface General Information
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
What is Contained in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-2
Chapter 1 FanMaster Overview
FanMaster Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FanMaster Externally Mounted Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
FanMaster Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FanMaster Application Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Integration of FanMaster into Building Automation Systems . . . . . . . . . . . . . . . . . . . . 1-12
Chapter 2 FanMaster Installation
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Chapter 3 FanMaster Configuration and Start Up
Using the PanelView C600 HMI Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Gather and Record Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Configure the FanMaster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
View Detailed Data Log Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Start or Stop Data Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Clear the Data Logs and Collect Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Chapter 4 Troubleshooting
FanMaster Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
FanMaster Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Appendix A Specifications and City Climate Profiles

Drives and FanMaster Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
City Climate Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Appendix B FanMaster Diagrams
Drawing Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Appendix C FanMaster Screens and Field Descriptions
Dashboard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Air Handler Unit Diagram Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Setup Screen #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Setup Date and Time Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Setup Screen #2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Setup Screen #3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-7
Supply Fan Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Return Fan Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-9
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
2
Fan Communication Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Cooling and Heating Setup Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10
Proof of Flow Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
Data Collection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13
User City Weather Data Setup Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14
Data Log #1 Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Data Log #2 Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Data Log #3 Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17
System Status Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18
Appendix D FanMaster Application Firmware Upgrades
Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Upgrade the FanMaster MicroLogix 1100 Controller Application Firmware . . . . . . . . . D-1
Upgrade the FanMaster PanelView Application Firmware. . . . . . . . . . . . . . . . . . . . . . . . D-3
Restart FanMaster with the New Application Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . D-8
Index

Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
Preface
General Information
Who Should Use This Use this manual if you are responsible for installing and/or operating the
Manual Allen-Bradley® FanMaster™ Energy Saving Package (FanMaster). You
must have a thorough understanding of installation and operation of HVAC
units, Building Automation Systems (BAS) and electrical circuitry and
components in order to successfully install this product.
What is Contained in this This manual provides installation and configuration information for the
Manual FanMaster product only. Refer to Reference Materialson pagep-2 for
information on associated products.
Before you begin the installation and configuration of FanMaster, it is
recommended that you read Chapter 1 - FanMaster Overview.
To install and configure FanMaster, complete the instructions in each of the
following chapters, sequentially:
– Chapter 2 - FanMaster Installation
– Chapter 3 - FanMaster Configuration and Start Up
Manual Conventions The following words are used throughout the manual to describe an action:
Word Meaning
Can Possible, able to do something
Cannot Not possible, not able to do something
May Permitted, allowed

Must Unavoidable, you must do this
Shall Required and necessary
Should Recommended
Should Not Not recommended
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
p-2 General Information
Reference Materials Rockwell Automation publications are available on the internet at
www.rockwellautomation.com/literature.
The following manuals are recommended for additional information:
Title Publication No.
PowerFlex 400 AC Drive Packages for Fan & Pump Applications Installation 22C-IN002
Manual
PowerFlex 400 Adjustable Frequency AC Drive for Fan & Pump Applications User 22C-UM001
Manual
PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions 20A-IN009
PowerFlex 70 AC Drives User Manual 20A-UM001
PowerFlex 700 Adjustable Frequency AC Drive Frames 0…6 Installation 20B-IN019
Instructions
PowerFlex 700 AC Drives Series B Vector Control User Manual 20B-UM002
PowerFlex 750-Series AC Drive Installation Instructions 750-IN001
PowerFlex 750-Series AC Drives User Manual 750-UM001
20-COMM-H RS-485 HVAC Adapter User Manual 20COMM-UM009
Wiring and Grounding Guidelines for PWM AC Drives DRIVES-IN001
PanelView Component HMI Terminals User Manual 2711C-UM001
MicroLogix 1100 Programmable Controllers User Manual 1763-UM001
For Allen-Bradley Drives Technical Support:
Title Online at . . .
Allen-Bradley Drives Technical Support www.ab.com/support/abdrives

Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1
Chapter
FanMaster Overview
FanMaster Description FanMaster provides a means for improving the energy efficiency of
Constant Air Volume HVAC units. Constant Air Volume HVAC units
typically draw in room air and mix it with a small amount of outside air.
This mixed air is forced by a fan through heating and/or cooling elements to
provide supply air back to the room at a temperature that makes up for
heating or cooling lost to the surrounding environment. This maintains
comfortable conditions for the building’s occupants and contents.
FanMaster improves the efficiency of a basic HVAC unit by providing the
following two additional control features:
(cid:129) FanMaster replaces a fixed speed fan motor starter with a Variable Speed
AC Drive which allows the fan speed to adjust to the actual HVAC
heating and cooling loads. The Law of Affinity states that the energy
required to operate a fan decreases by the cube of the actual speed
reduction. For example, a fan running at 80% of its maximum speed
requires about 50% of the energy needed to run the fan at full speed.
And, a fan running at 50% of its maximum speed requires only about
13% of the energy needed to run the fan at full speed. FanMaster’s ability
to monitor the HVAC operation and adjust the fan speed to the required
value provides considerable opportunity for savings.
(cid:129) FanMaster regulates the amount of outside air drawn into the HVAC unit
for the purpose of ventilation by monitoring the actual Carbon Dioxide
(CO ) level in the serviced space. This feature, known as Demand
2
Ventilation, maintains air quality while reducing the cost of heating or
cooling the outside air by reducing its volume.
The typical Constant Air Volume HVAC unit selected by the building's
original designer provides adequate heating, cooling, and ventilation for
worst-case conditions. The heating and cooling capacity are selected for the
coldest and hottest days anticipated and the ventilation capacity is designed
for maximum human occupancy. Since the weather is seldom at the

extremes in most locations and buildings are often occupied at less than full
capacity, FanMaster provides a savings opportunity by reducing the fan
speed and ventilation used by the HVAC unit when they are not required. In
addition, when the weather extremes do require maximum heating or
cooling or the CO level indicates the need for maximum ventilation,
2
FanMaster returns the fan to its original full speed and ventilation to the
original designed value until conditions are such that it can once again
reduce the fan speed and amount of outside air ventilation.
FanMaster has been designed for installation into an existing HVAC system
with minimal interface with the existing controls. FanMaster does not
replace or interfere with the existing controls which continue to regulate
room temperature. In addition, FanMaster can also be installed and used in
an evaluation only mode (without a fan drive). This mode allows the
FanMaster energy savings calculator to provide an estimate of potential
savings, prior to performing a full installation.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1-2 FanMaster Overview
FanMaster Externally Temperature Sensors
Mounted Components
Two temperature sensing probes are provided with FanMaster. These probes
are essential to FanMaster because the measured difference in temperature
between these sensors provides the command signal for the fan speed. The
temperature sensors are typically mounted on the outside of the Constant
Air Volume HVAC unit, with the sensing probe penetrating into the air flow
inside through a hole drilled into the side of the HVAC enclosure.
The placement of the Mixed Air sensor should be selected after examining
the interior of the HVAC unit to ensure that the probe is located in a position
that will accurately measure the temperature of the combined outside and
return air before entering the heating and cooling section. Avoid a location
that is in the upper, lower or edge portion of the air stream and one which
may be unduly influenced by the air entering the unit from the outside air
damper. If the Mixed Air temperature probe does not accurately reflect the
average temperature entering the heating and cooling elements, the fan
speed will not be set properly.
The supply air sensor should be mounted from 6 inches to 5 feet
downstream of the final heating or cooling element. Because the
temperature of the air can be warmer at the top of the air stream and cooler
at the bottom, the probe should be mounted as close to the vertical center of
the air flow as possible.
Carbon Dioxide Sensor
The CO sensor (if installed) is usually mounted in the room return air flow
2
of the HVAC unit prior to mixing with outside air. Alternatively, the CO2
sensor can be mounted directly on the return air duct work serving a specific
area that is most likely to be affected by high CO2 concentrations during
occasions of high occupancy. This will ensure that FanMaster will allow full
fan speed and normal ventilation when and where it is most needed. This is
the most typical installation.
Alternatively, the CO sensor can be mounted directly in the conditioned
2
space in an area that is most likely to be affected by high CO
2
concentrations during occasions of high occupancy. This will ensure that
FanMaster will allow full fan speed and normal ventilation when it is most
needed.
It may be desirable to invest in individual CO room monitors for critical
2
locations. It has been found that certain buildings lack adequate ventilation
prior to installation of FanMaster. If FanMaster seems to be running in CO
2
override even during periods of low occupancy, it is advised that you seek
help from an HVAC air quality professional for advice on how to best
rectify the ventilation problems.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
FanMaster Overview 1-3
Pressure Sensor (Optional)
In certain applications it may be necessary or desirable to maintain a
positive building pressure relative to the outside air. A pressure sensor can
be ordered with FanMaster which monitors the differential pressure
between the inside and outside air. When the differential pressure is lower
than a user specified setpoint, the FanMaster will override to 100% fan
speed to try to restore the desired minimum pressure differential. One
typical scenario where pressure override might occur is when a loading
dock door is opened to allow for a delivery, and additional airflow is
required to restore the pressure differential when the door closes. The sensor
requires connection to two lengths of 1/4 inch OD plastic tubing which
sample the inside and outside air pressure at their respective termination
points. You may need to experiment with the location of the tubing since
normal wind and airflow often causes localized air pressure deviations
around a building which may result in inaccurate pressure measurements.
You may find that the HVAC unit fan speed has no measurable affect on
building pressure. In this case turn off the pressure mode completely and do
not use the sensor.
When using a pressure sensor the Constant Ventilation mode described
below is not available.
Damper Position Indicator Switch
Many existing HVAC systems have a feature known as “economizer mode”
or “free cooling mode”. These systems monitor the outside air temperature
and humidity and when conditions are such that the outside air can be used
to provide cooling (instead of using the cooling element) the existing typical
system will open the outside air damper fully to allow maximum use of this
“free” cooling. FanMaster uses a Damper Position Indicator switch to
indicate when the existing control system is in economizer mode. The
switch is installed on the outside air damper in a location that causes its
contacts to close when the damper opens beyond the normal 10%
ventilation position.

In order to take full advantage of economizer mode, FanMaster increases
the speed of the fan to 100% until the existing control determines that
economizer mode is no longer appropriate. The economizer control will
then return the damper to its normal ventilation position and the contacts in
the damper position indicator switch will open. This signal is sent to
FanMaster, which allows the fan to return to its normal reduced speed and
damper override functions.
The switch must be installed in a position that will actuate when the damper
opens. It may be mounted directly on the damper blades, on the damper
actuator arms or linkage, or on the center axle of a damper blade section.
Because there are many different damper systems in use, the installation
may require fabrication of a custom linkage or mounting method if no
suitable location is available.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329
1-4 FanMaster Overview
Fan Starter Current Sensor
This device is used only when FanMaster is installed in evaluation mode.
The current sensor device is designed such that one wire lead of the existing
fan motor passes through its center. The current sensor has a switch that
actuates when it senses current flow in the motor wire, indicating that the
fan motor has been started by the existing control system. The actuated
switch identifies when the HVAC unit fan normally runs so the FanMaster
calculator can take into account the HVAC normal hours of operation and
more accurately project monthly cumulative savings.
Fan Starter Hard-Wired Interconnection
This device is used only when FanMaster is installed with a drive.
FanMaster requires a start signal from the existing BAS system in order to
know when to start and stop the fan. The control signal on the coil of the
existing fan motor starter provides this signal. The starter coil signal is
typically 115V AC or 26V AC. Two interposing relays, one that
accommodates each of these voltages, are shipped with FanMaster (120V
AC relay already installed at position CR4). Other control voltage relays are
available from Rockwell Automation.
FanMaster Operation Fan Speed Reduction
With the installation of FanMaster, the existing HVAC control system
continues to maintain room temperature by monitoring its own temperature
sensors and controlling the heating and cooling elements. FanMaster
provides new, independent temperature sensors mounted in the airflow of
the HVAC unit. These sensors allow FanMaster to determine if the existing
controls are requesting heating and cooling and to adjust the fan speed to a
value appropriate for the amount of heating and cooling required.
As the existing controls call for more heating or cooling (as determined by
the amplitude of the temperature differential measured before and after the
heating and cooling elements), FanMaster responds by increasing the fan
speed. As the amount of heating or cooling required decreases, the
temperature differential decreases and so does the FanMaster fan speed. If
the existing controls are not calling for heating or cooling, then there is no
temperature differential across the heating and cooling elements and
FanMaster reduces the fan speed to a user specified minimum speed.
Reducing the HVAC unit’s fan speed when not calling for maximum heating
or cooling results in significant savings in the energy required to run the fan,
according to the Law of Affinity.
Allen-Bradley® FanMaster™ Energy Saving Package Installation Manual - Publication FANM-IN001B-EN-P – December, 2009 PN-65329